Fiber product



Dec. 22, 1931. A. GERAR-D ET AL FIBER PRODUCT Filed May 9, 1928 2 Sheets-Sheet lNVENTORS Au gust Gerard urice Weisman Dec. 22, 1931. A, GERARD ET AL 1,837,261

7 FIBER PRODUCT Filed May 9, 1928 z sheets-sne e-c 2 INVENTORS v Augus'l Gerard Maurice isman "ATTQR ucts.

One object of the invention is to produce Patented Dec. 22 1931 UNITED STATES,

PATENT OFFICE AUGUST GERARD, 0F READING, AN MAURICE WEISMAN, OF BRIGHTON, MASSACHU SETTS, ASSIGNORS, BY DIRECT AND IVIESNE ASSIGNMENTS, TO COTTON-WOOD PROD- UCTS, INC., 01? READING, MASSACHUSETTS, A CORPORATION OF MASSACHUSETTS FIBER PRODUCT Application filed May 9, 1928. Serial No. 276,303.

This invention relates to fiber products having cushioning or insulating characteristics, and to methods of making such prodcushioned pads for use in the covers of candy boxes and the like.

Heretofore, efforts have been made to manufacture cushion pads, and the like, from Wood pulp fiber in a simple and inexpensive manner, but difficulties have been experienced in making an adequate, coherent and rugged pad, owing to the short lengths of thefibers and the difliculties' of joining the fibers together in such a manner as to produce the desired resiliency.- I

An object of the present invention is to overcome these difficulties and to provide an efficient, durable and easily constructed cushioned pad or insulating product of much lower cost than that of the usual cushioned products now available.

relatively small particles consisting of separate fibers of substantially completely disinte'grate'd paper and of small flakes of incompletely disintegrated paper having a greater maximum length than that of said fibers. These particles are produced in such roportions that when thoroughly interming ed, the

fibers form a soft wedding between the flakes,

and the resulting conihination consists of flakes dispersed threugheu saft wedding in interlocking relationship therewith.

A laminated product having cushioning and insulating characteristics may be made by depositing a cementitious material on one surface of apiece of sheet fabric, depositing the above referred to flakes and fibers as a cushioning layer on the resulting cementitious surface, and pressing the particles so deposcementitious material on their inner surfaces,

thereby producing a cushion layer between the two fabric layers. The resulting lami nations are then split medially of the intermediate cushioning layer .to produce two separate laminated sheets,each having a fabric layer and a cushioning layer cemented thereto. The cleavage surfaces, exposed by the fissure in the cushioning layer, are given a deposit of minute droplets of cementitious material and are then restored into face to face contact and cemented together.

- These and other objects and features of the invention will be understood more clearly from the following detailed description in connection with the appended drawings, in which:

Fig. 1 is a schematic perspective View of one form of. apparatus adapted for making the product of the present invention, the front sides of portions of the apparatus be-, mg removed to expose to view the interior thereof, and portions being shown in cross section.

Fig. 2 is anenlarged plan view of a typical dry paper.

Fig. 3 is an enlarged cross sectional view of the flake of Fig. 2.

Fig. 4 is an enlarged view showing a plurality of separate fibers of substantially completely disintegrated paper.

Fig. 5 shows on a larger scale, an axial section of a portion of the disintegrator rotor of Fig. 1.

Fig. 6 is an enlarged perspective view of a finished cushioned pad or insulating product.

Fig. 7 is a perspective view showing a modification of a portion of Fig. 1, adapted to provide a fabric layer between two cushioning or-iusulating layers.

Fig.- 8 is an elevation of a different type of machine from that of Fig. 1, portions of the machine being shown in section, and the front frame of the machine being removed in order more clearly to expose to view the details of the machine.

Fig. 9 shows on a larger scale, an axial section of the disintegrator rotor of Fig. 8.

Fig. 10 is a side view of one of the hammers shown in Fig. 9.

. Fig. 11 is a perspective view of a modification of apparatus for producing droplets of cementitious material.

Referring to Fig. 1, paper, such as waste paper and particularly old newspapers or other fabric of similar character, are deposited while substantially dry into the receiving hopper 1, from which the paper feeds to the disintegrator 2, of the beater type, having the rotor shaft 3, upon which are mounted the radial disks 4, keyed fast to the shaft. Bolts 5, mounted in equally spaced relation near the periphery of disks 4, support the metal hammers 6, preferably of rectangular block shape, which are free to swing indedependently of each other on bolts 5, as an axis, and are preferably made of wear-resisting material such as cold rolled or hardened steel, for example.

Shaft 3 is rotated at high speed by any suitable source of power not shown, the speed being preferably several thousand revolutions a minute so that hammers 6 tend to assume positions radial to shaft 3, as a result of the centrifugal force. The rapid rotation of rotor 3 disintegrates the paper by beating it and tearing it into relatively small fragments consisting of flakes 60 such as shown in Figs. 2 and 3, and separate fibers 61, Fig. 4. The flakes ordinarily have numerous small partially freed fibers extending therefrom, as shown in Figs. 2 and 3. The separate fibers 61, shown in Fig. 4, consist of substantially completely disintegrated paper, and are so short that they do not combine with each other with very appreciable coherency when intermingled with each other.

The separate fibers and all the flakes below a predeterminted size are selected by sifting them through the screen 7 in the base of the disintegrator. The openin s through screen 7 are so chosen that the fla es passing therethrough are relatively small, but have a maximum length greater than that of the fibers 61. In an actual practical case, it was found that numerous flakes of average size had a maximum length of from one-eighth to three-sixteenths of an inch. but it is to be understood that this illustration is given merely as an example of workable sizes of flakes, and that the flakes may be varied somewhat from these sizes, depending upon the character of the paper used and of the desired product. The passage through the screen is facilitated by the churning action within the disintegrator and by the suction roduced by the motor driven fan 8 which lows the air together with the sifted particles floating thereon through conduit 9 in the direction-shown by the arrowed line, the particles being dischar ed into the large storage hopper 10 which may have the glass top section 11 for inspecting the contents of the hopper.

Paddle wheel 12, located near the lower part of hopper 10, rotates to mingle the particles in the hopper, and aids their movement toward paddle wheel 13, which slowly rotates to periodically discharge definite quantities of the particles into the trough-like conduit 14, connecting with conduit 15, discharging into the rotating fan blower 16, which draws a strong current of air through conduits 14 and 15, and then blows it into conduit 17 in the direction indicated by the arrowed line.

The particles of disintegrated paper float along with the air stream into conduit 17, and are discharged into the upper part of hopper. 18, which has the inner walls 19 and 20 converging toward each other. The opening between the lower ends of walls 19 and 20, is substantially closed by the feed roll 21, which slowly rotates in a counter-clockwise direction andhas a multiplicity of short projecting teeth 22, extending from the periphery thereof, to engage the particles in the hopper and feed them as a stream down the inner wall 19. The thickness of this stream is controlled by rotation of the hand screw 28, threaded into the outer wall of hopper 18, thereby adjusting the position of wall19 relatively to feed roll 21. Paddle wheel 24, placed closely above roller 21, retates to churn the particles in hopper 18, and aids the movement of the particles toward roller 21. 1

Air entering hopper 18 from conduit 17, discharges through the coarsely woven cover 25 of burlap, or other suitable material. adapted to prevent escape of the particles. When the hopper becomes completely filled, the right hand end of conduit 17 is closed by the accumulation of particles therein, and the current of air and particles is automatically shunted away from hopper 18 through the upright conduit 26, which discharges through conduit 27 into the top of hopper 10, thus preventing the production of excessive pressure within hopper 18, and tending to maintain a uniform stream of particlesfrom roller 21. As long as the passageway into hopper 18 remains clear, the stream of particles from conduit 17 sweeps into the hopper without appreciable loss through conduits 26 and 27. A rapidly rotating toothed wheel 28 near the discharge end of hopper 18, thoroughly intermingles the particles as they leave the hopper. A roll 29, of relatively thick flexible sheet fabric 42, such as paper, rotates on shaft 30. and a roll 31 of relatively thin flexible sheet fabric 43, such as paper, rotates on shaft 2? The two-sheet strips 42 and 43, progressively advance longitudinally over freely rotatable rollers 33 and 34. A deposit of cementitious material such as shellac, sodi 5 um silicate, glue, 'or other suitable material, preferably in thin liquid form to facilitate the production of minute droplets, is deposited on the inner surfaces of the'sheets. The sprays 35 and 36, produced by the banks.

of nozzles 37 and 38 directing atomizing blasts of air past the nozzles 39 and 40, which discharge cementitious material, may be employed for producing the deposit of cementiwadding' between flakes 60, Figs. 2 and 3, when thoroughly mingled together, as in stream 41.

It has been found desirable in many cases, to so position rollers 33 and 34 in relation to stream 41 that the particles fall more directly upon-sheet 43 than upon sheet 42,01" so that the particles are first carried on sheet 43 by first adhering thereto. The particles 35 deposited upon sheet 43 then feed into cementing contact with sheet 42 between-rollers 33 and 34. It will be notedin Fig. 1, that stream 41 is shifted slightly to one side of the gap between. rollers 33 and 34 so that the particles fall more directly toward-sheet 43 than sheet 42. a

The cushioning-layer; after. tween rollers 33 and 34 'is split medially; of;

the layer, by-feeding sheets 42' and 43 away 44 and 45, the sheets 42 and 43 being then converged toward each other again. The

cleavage surfaces of*t-he fissure rod c djgq, layer 41 are then given-a de of; mmutl. 60 cementitious droplets by the sprays or clouds of droplets 46-produced by'a bankofnozzles 47, directing blastsv of air past ines 48, charging cementitious materiaL' Thea'twe sections of layer 41 are then rest redinmface to face contact with each other 'byjfeeding the combinedlaminations between frag,

1y rotatablerollers 49 and 50. Drivingi'rolls 51 and 52'--progressively advancesheets-42".

and 43 with layer 41 therebetween, and temporarilycompress the cushioned laminations to facilitate the cementing of the particles and layers. The pressure of roll 52 toward roll 51, is controlled by rotation of nuts 53 threaded on screw bolts 54 fast to the frame 55; Nuts 53' vary the compression of helical separate fibers 61, Fig. 4, as to form a softsprings 56, pressing on the bearings of roll- The shear blade 57 rotating on shaft 58 in a counter-clockwise direction, coo erates.

with the fixed shear blade 59 to cut t e finished cushioned product into pieces of desired length, a sample ofsuch a piece being shown in'Fig. 6. It will be noted that the sheet. 42 is represented in Fig. 1, as being appreciably thicker than sheet 43, but it is to be understood that the thickness of either sheet may be varied between wide limits according to the desired use of the finished product.

In Fig. 6 the flakes 60 will be seen to be in interlocking or dovetailed relationship with each other. The separate fibers 61 form soft wadding between the flakes and are locked in place by flakes 60, as well as by the cementing bond with the sheets 42 and 43, and between the particles in the vicinity of the sheets and of the cleavage surfaces of the fis- I sure in layer 41. The beating, churning and mingling of the dry particles tend to produce curls and kinks therein, thus improving their cushioning and interlocking. characteristics.

Owing to the different sizes," shapes, and positions of the particlesmakingup cushloning layer 41, and the method by which the cementitious material is applied to the parof the particles are bonded together, andv as a result, the particles are free to bend and holes, portions only of the cementable parts slide on one another between their cemented portions, so that the desired cushioning characteristics may be obtained. The loose cel- .lular structure between the uncemented porinsulation. By leaving portions of the particles uncemented, the natural sp'ringiness of the ;-'pa'rticles ;is preserved to a large extent,

and an efficient and durable cushioning and 45 from each other, over freelyrotatable rollers insulating product is produced. The cush- -:iofn .ed pad of Fig. 6, has been found to be particula rly' adapted for use in-the paper ox industry especially in making the cash ioned tops of candy boxes, and is also useful as, a sheathing paper, and as insulation against. the-transmission of sounds'and heat or cold, or for packing. The method of mak- .ing the cushioned product is simple, and of .low. cost, whi'lethe-materials employed are without cementing the laminations together between rollers 49, 50, 51 and 52.

Instead of' cementing the particles in stream 41 to sheets 42 and43 they may be discharged from hopper 18 and used in bulk for cushioning and insulating purposes, the flakes 60 functioning similarly to those shown in Fig. 6.

ment between the two sections 65 and 66 of having bifurcated outer ends.

the cushioning layer.

Banks of spraying nozzles 67 and 68, respectively, deposit cementitious material on the cleavage surfaces of layer 41 and at the same time on the two surfaces of sheet 62, so that the combined laminations passing between rollers 49 and 50 are cemented together as a single unit. The resulting product possessed greater strength than that of Fig. 6, and may be used similarly thereto.

The machine of Fig. 8 has the input hopper 1, into which is placed the dry paper to be disintegrated. The disintegrator 2, has a rotor 69 constructed somewhat differently from that shown in Fig. 1. The shaft 3 has the radial disks 4 ke'yed fast thereto, Fig. 9. Pairs of disks 4 support the fixed shafts 70, upon which are freely swivelled the arms 71, Between each pair of ends, is supported the. notched hammer disks 7 2, freely rotatable on pivots 73.

' The paper is disintegrated by high speed rotation of rotor 69, and particles below a predetermined small size, driven by the churning action of rotor 69, discharge through conduit 74, into hopper 75, having the inner wall 76. Disintegrated particles, consisting of flakes and fibers, discharge through the gap between the lower end of wall 76 and the wall of hopper 75, and are deposited on the top of feed roll 77, having the small projecting teeth 78. Roll 77 rotates slowly, as shown by the arrow, and feeds a loose stream of particles 79 from the hopper, allowing the particles to fall freely through the air in more or less spaced-apart relationship into the bottom of the V-shaped trough, formed by the sheets 42 and 43, of flexible fabric, such as the paper in sheets 42 and 43, Fig. 1. Sheets 42 and 43 feed longitudinally into confluency between driving rollers 51 and 52. The particles in stream 27, feed through a fog like cloud 84 of cementitious droplets, formed by nozzles 85 discharging compressed air from blower 88, past nozzles 86 which discharge cementitious material from the reservoir 87.

A valve 83 for each of the nozzles 85 and 86, is adjusted so that the cementitious liquid is very finely divided into droplets which tend to float on the air as'a fog-like cloud and become deposited on the particles in stream 79 passing therethrough. By making the droplets very fine a cementitious deposit can be produced with less blowing of the particles from their proper positions in stream 7 9 than when the spray is deposited with force 011 the freely falling particles. An advantage of this method of applying the cement to the particles in stream 79, is that the cement tends to deposit in spaced apart relationship on the particles, so that portions only of their cementable parts eventually becomecemented together. At the same time, sheets 42 and 43, which confine the droplets in cloud 84, to the region of stream 79, receive a deposit of cementitious material.

The particles in stream 79 are brought together between sheets 42 and 43, and form the cushioninglayer 80. The pressure of roll 52 toward roll 53 aids the cementing of the particles, and of the layer 80 to sheets 42 and 43, thus producing an efficient cushioning or insulating unit.

Fig. 11- shows a form of apparatus adapted for producing and depositing minute cementitious droplets, and particularly for depositing the droplets on the particles of disintegrated paper in. stream 7 9, with minimum disturbance to the positions of the particles. The casing 89 is partly filled with the thin liquid cementitious material 90, forming a pool in the lower portion of the casing. A roller 91, dipping tangentially into the liquid 90, rotates in a clockwise direction, and carries an adhered coatof the liquid 90 on its periphery. Any excess of the liquid on roller 91 is removed by the wiper 92, which also helps to spread the liquid so that a film of uniform thickness remains on the roller. A shaft 93, rotating at high speed in a counterclockwise direction, has the bristles-or stiff wires 94, extending radially therefrom. The outer ends of bristles 94 brush over the periphery of roller 91, and throw off a spray 95 of minute droplets of the cementitious li uid,

cementitious material, in place of any of the spraying or atomizing apparatus shown in li s. 1, 7'and 8.

arious modifications of the details described herein as illustrative of the invention, will be a parent to those skilled inthe art, without I eparting from the principles disclosed herein. For example, variations may be made in the thickness and character of the fabric or material employed in the backing sheets, or in the number and thickness of lay-' ers in the product. Obviously, a finished laminated sheet, such as produced by the method of Figs. 1, 7, or 8, may be fed into the machines in place of sheet 42, thus making additional cushioning layers in the final roduct, to produce a product of greater 1:- ickness, having greater cushioning and insulating characteristics than that of the product shown in Fig.6.

The method and machine are not claimed herein, being claimed in our co-pending application Serial No. 524,514, filed March 23, 1931, which is a division hereof.

We claim: a

1. A cushioned fiber product consisting of a layer of particles of partially disintegrated I throughout said waddin g in interlocking relai tionship with each other and with said waddin I 3. A laminated fiber product having a layer of sheet fabric, and a cushioning layer cemented thereto consisting of particles of partially disintegrated paper and other particles of substantially completely disintegrated paper intermingled with said first particles as a soft wedding. p

4. A laminated fiber product having a separate articlesinto cementing relationship with sai .face, the outer faces of said disintegrated paper layers being disposed in face to face contact with eachother and cemented to ether.

n witness whereof, we hereunto subscribe our names, this 7th da of Ma 1928.

AUGl IST G RARD. MAURICE WEISMAN.

layer of sheet fabric, and a cushioning layer 4 cemented thereto, consisting of separate fibers of disintegrated paper and relatively small flakes of paper intermingled with said fibers,

said fibers and flakes being cemented together at portions only of their cementable parts.

5. A: cushioned pad having two layers of sheet fabric, and an intermediate layer'consisting of relatively short fibers grouped together as a soft wadding and having relatively' small paper flakes of greater length than's aid fibers,dispersed throughout said wedding in interlocking relationshi -with each other and with said wedding, sai intermediatelayer beingcemented .to said fabric 6; A laminated fiber product having .two layers of sheet fabric, and an intermediate cushioning layer consisting {of particles of vdisintegrated paper disposed between said fabric layers and cemented thereto, said intermediate layer having a medial fissure, pro-i duced by longitudinally splitting the layer after said-layer is cemented 'to said fabric,

the re 'stering-faces of bond together.

7. A laminated fiber" product having two layers of sheet fabric, each having a cementitious face andhaving a separate cushioning layer-of disintegrated paper deposited as said fissure being 

